40ft Broadcast Studio Containers for Commonwealth Games Case Study

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40ft Broadcast Studio Containers for Commonwealth Games Case Study

Our client approached us with a brief to provide a three-tier structure made out of 6 x 40ft new high cube shipping containers. The structure had to blend in with buildings surrounding it in order to have planning permission passed. The structure was to be used for a commentary box for a high profile event. Our client was an events agency who provided support to large multi-national companies during high profile sporting events. The client had little brief to work from and no designs yet the lead time was extremely short. Lion Containers Fabrications Limited quickly built the specification and ensured that the project came to fruition within a very short amount of time. The 6 x 40ft new high cube containers were modified as follows:

6 x 40ft new high cube containers to be stacked on site creating a three high, two deep structure.

One 40ft panel was removed from each of the containers to create a modular structure and link the units together in order to maximise space. Due to the fact that the containers were then to be stacked three high, structural loads had to be thoroughly researched and the containers re-enforced. The apertures were surrounded with box section and were made suitable for later joining on the customers site.

The external finish of the container had to match other building within the vicinity in order to achieve planning permission. Therefore, a strict specification was provided, and adhered to with the units being clad in tantalised timber with a 10mm spacing. Removable cladded panels were fitted over the cargo doors of the lower containers in order to achieve easy access for loading and un-loading of heavy items within the ground floor storage area.

Lighting and emergency lighting was installed throughout the structure. The installation was protected by a consumer unit and included an inter-container connection box so that the whole structure could operate together.

Seven 3.5KW air conditioning units and one 5Kw air conditioning unit were installed in order to keep an ambient internal temperature. The air conditioning was commissioned on site along with the units.

Partitions were fabricated from a timber frame lined with Celotex board in order to create separate rooms within each floor. For the purpose of sound-proofing, the partitions were lined with 12mm acoustic overlay board which was then painted matt black to assist with lighting during filming within the structure. No partitions were installed in the ground floor, this area was a general stores area. Two partitions were installed in the first floor which created three offices and two partitions were installed in the second floor, also creating three offices.

The walls, ceilings and cargo doors of each of the floors were lined with 12mm ply and insulated with rockwool insulaton. The roof of the second unit was also acoustically lined to assist with sound during filming.

All internal areas were re-painted matt black in order to assist with lighting during filming.

The standard marine ply floor of the containers were overlaid with ply which was then overlaid with light grey carpet tiles to give a plush feel within the structure.

Thirteen cable inlet apertures (8” diameter) were cut and surrounded with a steel collar in order to allow the clients cables to be run through and outside the structure.

Eight steel, single, high security and weather proof personnel doors were installed throughout each floor to the back of the structure to allow simple personnel access from the custom built staircase. Some of the doors had vision panels installed in order for personnel to see when filming was taking place.

Custom built, aluminium framed windows were procured and installed on site within pre-cut apertures and prior to the containers being stacked. The amazing views were maximised in the fitting of the windows. The windows varied in size but were enormous; they varied from 2500mm x 2500mm to 2500mm x 4500mm! The aluminium frames of the windows were carefully installed so that only the external cladding could be seen and not the aluminium frames.

Standard steel shuttered windows were installed to the ground floor storage compartment of the structure.

Our client required slightly more space on the second floor than could be provided with shipping containers. Therefore, a 4745mm x 1669mm cantilever section was custom built using the same building methods as a standard shipping container. This was self supporting to the containers on the second floor.

The staircase was the real engineering feat to this project! A custom built staircase was fabricated and installed with landings which served the first and second floor and helped to support the cantilever section. The staircase had 6mm chequer plate durbar treads and complied with Building Regulations Pt. K1 2002 & BS5395 Pt. 3 1985 Stairs, ladders and ramps. The staircase, landings and walkways were of all steel construction and powder coated to match the containers.

Lion Containers Fabrications worked very closely with the client to achieve the project, full drawings were provided throughout as well as regular progress visits and work in progress photographs. The units were delivered, stacked and weather-proofed by Lion Containers Fabrications and mechanically and electrically linked on site. The air conditioning was commissioned by Lion Containers Fabrications and the windows were installed on site as was the staircase with its landings and walkways. Significant project management was required as, due to the size of site and regular movements, the team had to hire mobile cranes, tele-handlers, cherry pickers and flood lights.